Repair including a chamfered bracket and a chamfered bracket component for reinforcing a damaged structural element made from composite materials

ABSTRACT

A repair for a structural element made from a composite material includes a bracket defining a first surface and a second surface. The first surface is adapted for facing the structural element. A chamfer is located on a first end of the bracket. An angle is defined between a plane of the chamfer and a plane of the first surface, the first surface of the bracket being adapted to be disposed adjacent to a side of the structural element. The repair also includes a sealant material between the bracket and the structural element, where the sealant material occupies a space established between the chamfer and the structural element.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This divisional patent application claims priority to U.S. applicationSer. No. 15/737,432, filed on Dec. 18, 2017, and which claims priorityto 371 International Patent Application No. PCT/GB2016/051814, filed onJun. 17, 2016, and which claims priority to GB patent application no.1511402.8, filed on Jun. 30, 2015, the entire content of all which areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention concerns a chamfered bracket component forreinforcing a damaged structural element made from a composite material.The present invention also concerns a method of repairing a damagedstructural element via a chamfered bracket. More specifically, thepresent invention concerns a method of repairing a damaged structuralelement in an aircraft using a chamfered, metal bracket.

DESCRIPTION OF THE BACKGROUND AND RELATED ART

In the prior art, when repairing a damaged structural element made froma composite material, it is customary to attach a metal brace or bracketto the structural element.

It is also customary to apply sealant to fill any gaps created betweenthe metal bracket and the damaged structural element.

It is understood that, when applying sealant to fill any gaps betweenthe metal bracket and the structural element, the sealant should beapplied to minimize the creation of air bubbles.

As should be apparent to those skilled in the art, if the sealant isexposed to a high voltage, such as might be experienced as a result of alighting strike, any gases trapped in an air bubble in the sealant mightbecome heated to a sufficiently high temperature to cause the bubble toburst. This may result in damage to the sealant and associatedcomponents.

Where bubbles are present in sealant in an aircraft fuel tank, there isan increased risk that the bubbles might burst, damaging the fuel-tightsealing of the fuel tank or creating an unwanted ignition risk.

Other potential difficulties associated with prior art repairs alsoshould be apparent to those skilled in the art.

Accordingly, an improved repair for improving sealing of a damagedstructural element made from composite material is desired.

SUMMARY OF THE INVENTION

The present invention addresses one or more of the deficiencies withrespect to the prior art.

In particular, the present invention provides for a repair for astructural element made from a composite material. The repair includes abracket defining a first surface and a second surface. The first surfaceis adapted for facing the structural element. A chamfer is located on afirst end of the bracket. An angle is defined between a plane of thechamfer and a plane of the first surface, the first surface of thebracket being adapted to be disposed adjacent to a side of thestructural element. The repair also includes a sealant material betweenthe bracket and the structural element. The sealant material occupies aspace established between the chamfer and the structural element.

It is contemplated that the bracket may defines a first side, a secondside, and a third side, the second side extending between the first sideand the third side. If so, the chamfer is contemplated to extend betweena first position on the first side and a second position on the secondside.

In one contemplated embodiment, the chamfer defines a chamfer thicknessas a distance measured from the first position to the second positionalong a line normal to the plane of the first surface. A bracketthickness is defined as a distance measured from the first side to thethird side along the line normal to the plane of the first surface. Thechamfer thickness is less than the bracket thickness.

Alternatively, it is contemplated that the chamfer is a first chamfer,the bracket including a second chamfer located on a second end of thebracket.

In another contemplated embodiment, a polyimide film is disposed betweenthe bracket and the structural element.

It is contemplated that the polyimide film may be positioned between twolayers of sealant material.

The bracket may be made from at least one of titanium, alloys oftitanium, aluminum, alloys of aluminum, iron, alloys of iron, steel,plastics, composite materials, and ceramics.

The angle of the chamfer is contemplated to lie between about 20°-70°.

The chamfer thickness is contemplated to be at least one of greater thanabout 0.020 inches (0.51 mm), greater than about 0.025 inches (0.64 mm),greater than about 0.030 inches (0.76 mm), greater than about 0.35inches (0.89 mm), and greater than about 0.4 inches (1.02 mm).

The ratio of the chamfer thickness to the bracket thickness iscontemplated to be at least one of about 0.50, about 0.45-0.55, about0.40-0.60, or about 0.35-0.65.

In another contemplated embodiment of the repair of the presentinvention, the repair also may include a second bracket with aconstruction identical to the first bracket, the second bracket beingadapted to be disposed adjacent to a second side of the structuralmember made from the composite material.

Still further, it is contemplated that the repair may include at leastone fastener adapted to connect the bracket to the structural member.

Another aspect of the present invention provides for a chamfered bracketsuitable for being connected to a structural element made from acomposite material. The chamfered bracket is contemplated to include afirst surface and a second surface, the first surface being adapted forfacing the structural element and a chamfer located on a first end ofthe bracket. An angle is contemplated to be defined between a plane ofthe chamfer and a plane of the first surface, the first surface of thebracket being adapted to be disposed adjacent to a side of thestructural element. The chamfer is contemplated to define a chamferthickness as a distance measured from a first position where the chamferintersects the first surface to a second position where the chamferintersects an end surface along a line normal to the plane defined bythe first surface. A bracket thickness is defined as a distance measuredfrom the first surface to the second surface along the line normal tothe plane defined by the first surface. The chamfer thickness iscontemplated to be less than the bracket thickness.

As with the repair, the chamfered bracket is contemplated to include asecond chamfer located on a second end of the bracket.

Concerning the chamfered bracket, it is contemplated that at least onelayer of sealant material may be applied to the first surface, such thatthe sealant material occupies a space established between the chamferand the structural element when installed.

Also concerning the chamfered bracket, a polyimide film may bepositioned between two layers of the sealant material.

For the chamfered bracket, the at least one layer of sealant materialmay be an interfay sealant.

It is contemplated that the chamfered bracket may be made from at leastone of titanium, alloys of titanium, aluminum, alloys of aluminum, iron,alloys of iron, steel, plastics, composite materials, and ceramics.

The angle of the chamfer(s) on the chamfered bracket is contemplated tolie between about 20°-70°.

The chamfer thickness for the chamfered bracket is contemplated to be atleast one of greater than about 0.020 inches (0.51 mm), greater thanabout 0.025 inches (0.64 mm), greater than about 0.030 inches (0.76 mm),greater than about 0.35 inches (0.89 mm), and greater than about 0.4inches (1.02 mm).

For the chamfered bracket, the ratio of the chamfer thickness to thebracket thickness may be at least one of about 0.50, about 0.45-0.55,about 0.40-0.60, or about 0.35-0.65.

The present invention also provides for a method for repairing a damagedstructural element made from a composite material. The method includesproviding a bracket defining a first surface and a second surface, thefirst surface being adapted for facing the structural element, and achamfer located at a first end of the bracket, where an angle is definedbetween a plane of the chamfer and a plane of the first surface. Themethod includes applying a sealant material to one of the first surfaceof the bracket and a side surface of the structural element, placing thebracket adjacent the side surface of the structural element such thatthe sealant material occupies a space established between the chamferand the structural element, and connecting the bracket to the structuralelement via a mechanical fastener.

It is contemplated, for the method, that the method also may includeapplying a film to the sealant material.

Further aspects of the present invention will be made apparent from theparagraphs that follow.

BRIEF DESCRIPTION OF THE DRAWING(S)

The present invention will now be described in connection with thedrawings appended hereto, in which:

FIG. 1 is a graphical, side view of the construction of a traditionalrepair for a damaged structural element made from a composite material;

FIG. 2 is a graphical, side view of a portion of a repair for astructural element made from a composite material, as contemplated bythe present invention;

FIG. 3 is a graphical, side view of the construction of a firstembodiment of a repair for a structural element made from a compositematerial, as contemplated by the present invention;

FIG. 4 is a graphical, side view of the construction of a secondembodiment of a repair for a structural element made from a compositematerial, as contemplated by the present invention; and

FIG. 5 is a graphical, side view of a chamfered bracket componentaccording to the present invention.

DETAILED DESCRIPTION OF EMBODIMENT(S) OF THE INVENTION

The present invention will now be described in connection with one ormore embodiments thereof. The discussion of the embodiments is notintended to be limiting of the present invention. To the contrary, anydiscussion of embodiments is intended to exemplify the breadth and scopeof the present invention. As should be apparent to those skilled in theart, variations and equivalents of the embodiment(s) described hereinmay be employed without departing from the scope of the presentinvention. Those variations and equivalents are intended to beencompassed by the scope of the present patent application.

FIG. 1 is a graphical, side view of the construction of a traditionalrepair 10 for a structural element 12 made from a composite material. Inthe non-limiting embodiment where the structural element 12 is anaircraft component, the structural element 12 may be a damaged stringer,frame member, spar, or other element, as should be appreciated by thoseskilled in the art. The structural element 12 may be connected to asubstrate 14, such as an aircraft skin for example, as illustrated inFIG. 1.

In order to reinforce the damaged structural element 12, the repair 10includes a bracket 16. In the illustrated prior art embodiment, thebracket 16 is made from metal and is L-shaped. As such, the bracket 16includes a vertical segment 18 and a horizontal segment 20. In theillustrated example, the bracket 16 is connected to the structuralelement 12 via a nut 24 and bolt 22.

As also illustrated in FIG. 1, a gap 26 exists between the bracket 16and the structural element 12. Air pockets may get trapped within thegap 26 between the bracket 16 and the structural element 12. These airpockets can be dangerous during a lightning strike, since currentconduction across the interface between the two parts may cause the airpockets to become super-heated and burst, which could possibly presentan unwanted ignition risk within an aircraft fuel tank.

To seal the gap 26, sealant 28 is applied. The sealant 28 bridges thegap 26 and forms a bead that extends from the top end 30 of the bracket16 to the top end 32 of the structural element 12.

However, due to constant sloshing of fuel within the fuel tank, the beadof sealant 28 can suffer from erosion and get worn down over time. Asthe bead of sealant 28 wears down, there is a risk that air pockets canform within the gap between the bracket 16 and the structural element12. More particularly, continued exposure to the flow of fuel within thetank across outer faces 30 and 32 of the repair and structural elementwill also tend to erode the sealant 28 applied to this interface,resulting in reduced protection of the interface with continued time inservice.

To avoid this possible outcome, among others, FIG. 2 illustrates oneaspect of the present invention. FIG. 2 provides an enlarged, graphicalillustration of a portion of a repair 34 according to the presentinvention.

As discussed in connection with FIGS. 3 and 4, the repair 34 of thepresent invention relies upon an L-shaped bracket 36 with a chamfer 38incorporated at the end 40 of the vertical segment 42 and a chamfer 44incorporated at the end 46 of the horizontal segment 48. In connectionwith the discussion of the present invention, it is noted that the terms“vertical” and “horizontal” are employed with reference to theorientation in the figures. The terms “vertical” and “horizontal” shouldnot be understood to be limiting of the present invention.

As illustrated in FIG. 2, the chamfer 38 extends from a first position50 on a first side 52 of the bracket 36 to a second position 54 on asecond side 56 of the bracket 36. The second side 56 of the bracket 36is located at the top end 40 of the bracket 36 and is, therefore, thetop side of the bracket 36 in this embodiment. It is noted that thefirst side 52 of the bracket 36 is the side facing toward the structuralelement 12. For clarity, the third side 58 of the bracket 36 is the sidefacing away from the structural element 12.

The thickness 60 of the chamfer 38 (also referred to as the chamferthickness 60) is the distance from the first position 50 to the secondposition 54, as measured along a line that is perpendicular (normal) toa plane defined by the first side 52. It is noted that, for theillustrated embodiment, the first side 52 is contemplated to be parallelto the third side 58. The second side 56 is contemplated to beperpendicular both to the first side 52 and to the third side 58. It isnoted that the orientations of the first side 52, the second side 56,and the third side 58 may differ from the construction illustratedwithout departing from the scope of the present invention.

As illustrated in FIG. 2, the thickness 60 of the chamfer 38 is lessthan the thickness 62 of the bracket 36 (also referred to as the bracketthickness 62). The bracket thickness 62 is measured between the firstside 52 and the third side 58 also along a line perpendicular (normal)to a plane defined by the first side 52. With this construction, thesecond position 54 lies on the second side 56, between the first side 52and the third side 58. It should however be appreciated that in analternative embodiment, the chamfer 38 may extend between the first side52 and the third side 58, such that the top end 40 is defined entirelyby the chamfer 38.

With the construction of the chamfer 38 described, it is contemplatedthat the angle 64 of the chamfer 38 will be about 45°. The angle 64 ismeasured as the angle defined between a plane defined by the chamfer 38and a plane defined by the first surface 52. In the alternative, it iscontemplated that the angle 64 may lie in a range between about 45°±2°,about 45°±5°, about 45°±7°, or about 45°±10° without departing from thescope of the present invention. In a further alternative, it iscontemplated that the angle 64 may lie anywhere in a range of between20° and 70° without departing from the scope of the present invention.

The thickness 60 is contemplated to be greater than about 0.020 inches(0.51 mm). Alternatively, the thickness may be greater than about 0.025inches (0.64 mm), greater than about 0.030 inches (0.76 mm), greaterthan about 0.35 inches (0.89 mm), or greater than about 0.4 inches (1.02mm) without departing from the scope of the present invention.

The ratio of the chamfer thickness 60 to the bracket thickness 62 iscontemplated to be about 0.50. In alternative embodiments, the ratio maybe between about 0.45-0.55, about 0.40-0.60, or about 0.35-0.65 withoutdeparting from the scope of the present invention. By relying on aratio, the present invention is considered to be scalable to anythickness of the bracket 36 without departing from the scope of thepresent invention.

It is noted that the construction and dimensioning of the chamfer 44 atthe end 46 is contemplated to be the same as the chamfer 38. However,the angle of the chamfer 44 is measured as the angle defined between aplane defined by the chamfer 44 and a plane defined by a bottom surfaceof the horizontal segment 48. The construction and dimensioning of thechamfers 38, 44 may differ from one another without departing from thescope of the present invention. It is also noted that the chamfer 44,like the chamfer 38, also faces the structural element 12 or thesubstrate 14 to which the bracket 36 is attached, as discussed ingreater detail with respect to FIGS. 3 and 4.

Reference is now made to FIG. 3, which illustrates a repair 64contemplated to fall within the scope of the present invention. FIG. 3illustrates a repair 64 that includes a first bracket 66 and a secondbracket 68. The first bracket 66 and the second bracket 68 arecontemplated to have the same construction as described in connectionwith the bracket 36. Here, the first bracket 66 and the second bracket68 are contemplated to have identical structures. However, to practicethe present invention, the first bracket 66 and the second bracket 68 donot need to be identical in construction.

As illustrated, the first bracket 66 connects to a first side 70 of astructural element 12. The second bracket attaches to a second side 72of the structural element 12. To facilitate discussion of the presentinvention, the construction of the repair 64 associated with the secondbracket 68 is provided in exploded detail. The construction of therepair associated with the first bracket 66, in contrast, is shown inthe assembled condition as might appear on an aircraft.

The first and second brackets 66, 68 are contemplated to be made frommetal. Suitable metals include, but are not limited to titanium, alloysof titanium, aluminum, alloys of aluminum, iron, alloys of iron, steel,plastics, composite materials, and ceramics. In the illustratedembodiment, the first and second brackets 66, 68 are made from titanium,which offers light weight and high strength for the repair 64. The firstand second brackets 66, 68 do not need to be made from the same materialto practice the present invention.

The first and second brackets 66, 68 are L-shaped in this embodiment.While the first and second brackets 66, 68 are illustrated as beingL-shaped, the first and second brackets 66, 68 may have any alternativeshape without departing from the scope of the present invention.

There are three layers between the first and second brackets 66, 68 andthe structural element 12. The first layer 74 comprises a first sealant,such as an interfay sealant. The second layer 76 is an interlayercomprising a polyimide. The third layer 78 comprises a second sealant,such as an interfay sealant. In the illustrated embodiment, the firstand second sealants are contemplated to be the same, but this is notrequired to practice the present invention.

The layers of interfay sealant 74, 78 may be any suitable sealant thathelps to insulate against electricity transfer. More particularly, thelayers of sealant 74, 78 provide the dual function of preventinglightning strike from transferring into the skin of the aircraft as wellas to reduce the air pockets between the brackets 66, 68 and thestructural element 12. In addition, the layer of polyimide 76, isincluded between the composite structural element 12 and the metallicbrackets 66, 68 in order to isolate the metal from the carbon in orderto avoid corrosion. The layers of material 74, 76, 78 may be anysuitable materials known in the art for at least partially achievingthese functions.

While the present invention is described in connection with the firstlayer 74, the second layer 76, and the third layer 78, the presentinvention should not be considered to be limited solely to a three layerconstruction. At a minimum, it is contemplated that the presentinvention will incorporate at least the first layer 74. Alternatively,the present invention may incorporate more than three layers, asrequired or as desired.

The brackets 66, 68 may be pre-fabricated to incorporate all threelayers 74, 76, 78. In this contemplated embodiment, the brackets 66, 68and the layers 74, 76, 78 are presented as chamfered bracket components118, a typical example of which is illustrated graphically in FIG. 5 inexploded detail. To effectuate the repair 64, therefore, all that isnecessary is for the chamfered bracket components 118 to be placedagainst the damaged structural element 12 to reinforce the damagedstructural element 12.

To construct a chamfered bracket component 118, the first layer 74 isapplied to the bracket 66, 68. The second layer 76 is then applied tothe first layer 74. The third layer 78 is then applied to the secondlayer 76. The chamfered bracket component 118 may then be positionedadjacent to the damaged structural element 12, as an integral component,to effectuate the repair 64, for example.

Alternatively, the repair 64 may be assembled in situ on the aircraft byconstructing the repair 64 directly onto the structural element 12.Here, it is contemplated that the third layer 78 of interfay sealantwill first be applied to the damaged structural element 12. As notedabove, the damaged structural element is contemplated to be a stringer,brace, spar, or other element made from a composite material. After thethird layer 78 of sealant is deposited, the second layer 76 is placedthereon. After placement of the second layer 76, the first layer 74 isdeposited over the second layer 76. The bracket 66, 68 is then fittedonto the first layer 74, in contact with the first layer 74.

As necessary, the repair 64 may be cured by any methodology understoodby those skilled in the art. In the alternative, it is contemplated thatthe repair 64 may be effectuated without curing. If curing is required,it is contemplated that the curing may require application of heatand/or a vacuum to the repair 64. Where a vacuum is required, it may benecessary to position a vacuum bag over the repair 64, as should beappreciated by those skilled in the art.

In the illustrated examples, the first layer 74 may be applied as aliquid, as a solid, as a powder, or as a film. It is contemplated thatthe first layer 74 will be applied as a liquid or as a film, but thepresent invention should not be considered to be limited solely to thesecontemplated constructions.

The second layer 76 is contemplated to be applied as two sheets ofpolyimide film, which are designated as a first film 80 and a secondfilm 82. As should be apparent to those skilled in the art, however, thesecond layer 76 may be applied as an integral, single layer withoutdeparting from the scope of the present invention. In addition, whilethe second layer 76 is contemplated to be a polyimide, other materialsmay be substituted therefor without departing from the scope of thepresent invention.

Like the first layer 74, the third layer 78 may be applied as a liquid,as a solid, as a powder, or as a film, as should be apparent to thoseskilled in the art. It is contemplated that the third layer 78 will beapplied as a liquid or as a film, but the present invention should notbe considered to be limited solely to the contemplated constructions.

The third layer 78 is contemplated to differ from the first layer 74 inthat additional sealant beads 84, 86, 88 are provided on the first layer74. The first additional sealant bead 84 is provided at the top end ofthe first layer 74, adjacent to the top chamfer 38. The secondadditional sealant bead 86 is provided at the corner of the structuralelement 12 where the structural element forms a T-junction (or where thestructural element 12 and the substrate 14 form a T-junction). The thirdadditional sealant bead 88 is provided at the bottom end of the firstlayer 74, adjacent to the bottom chamfer 44. The additional sealantbeads 84, 88 provide additional sealant material to fill the gapsestablished by the chamfers 38, 44. As should be apparent, theadditional sealant bead 86 provides additional sealant material to fillthe corners established between the vertical segment 104 and thehorizontal segments 108 of the structural element 12.

While not limiting of the present invention, it is contemplated that thesealant beads 84, 88 cooperate with the chamfers 38, 44 to establish adurable seal between the brackets 66, 68 and the structural element 12.Since the beads 84, 88 are positioned between the chamfers 38, 44 andthe structural element, they are protected from sloshing within the fueltank such that even if erosion of a top portion of the beads 84, 88should erode, there is still sufficient sealant within the chamfer toprevent air pockets from forming between the brackets 66, 68 and thestructural element 12. In particular, the chamfers 38, 44 establishspaces with gradient openings that accommodate the sealant beads 84, 88,providing a larger area of attachment between the brackets 66, 68 andthe structural element 12 and/or substrate 14, and less risk of airpockets forming. As a result, there is a smaller likelihood of damage ifthe repair 64 is exposed to high voltage. Finally, the chamfers 38, 44establish locations where greater thicknesses of sealant are depositedby comparison with the repair 10. In particular, the sealant accumulatesin the spaces created by the chamfers 38, 44, which does not occur inthe prior art repair 10. As a result, there is a smaller likelihood thatthe sealant 84, 88 might be removed inadvertently from the repair 64, asmight occur in the prior art construction. (With renewed reference toFIG. 1, it is noted that the sealant 28 might be inadvertently removedif, for example, a maintenance person were to strike the sealant 28 witha tool.) In summary, the chamfers 38, 44 offer a number of advantagesover the prior art.

In an alternative, contemplated embodiment, it is contemplated that oneor more of the additional sealant beads 84, 86, 88 may be provided inconnection with the third layer 78 without departing from the presentinvention.

FIG. 4 is a graphical side view of a second embodiment of a repair 90according to the present invention. This embodiment is contemplated tobe the same as the first embodiment illustrated in FIG. 3. However, inthis illustration, two fasteners 92, 94 are added.

In the embodiment illustrated in FIG. 4, the first fastener 92 comprisesa first threaded member 96 and a first nut 98 that connect the verticalsegments 104 of the brackets 66, 68 to the vertical segment 106 of thestructural element 12. The second fastener 94 comprises a secondthreaded member 100 and a second nut 102 that connects the horizontalsegment 108 of the bracket 66 to one of the horizontal segments 110 ofthe structural element 12 and also to the substrate 14.

As should be apparent to those skilled in the art, the horizontalsegment 108 of the second bracket 68 also may be bolted to the other oneof the horizontal segments 110 of the structural element 12 and thesubstrate 14 without departing from the scope of the present invention.

As illustrated in FIG. 4, the first threaded member 96 may be a bolt.The second threaded member 100 may be a flat-headed screw. The exactconstruction of the threaded member 96, 100 is not critical to thepresent invention. Different threaded members 96, 100 may be selectedbased on the positioning of the threaded member 96, 100 and othervariables that should be apparent to those skilled in the art.Separately, it is contemplated that any suitable fastener may besubstituted for the fasteners 92, 94 without departing from the scope ofthe present invention.

As also illustrated in FIG. 4, it is contemplated that selected, exposedends of the threaded members 96, 100 may be encased in sealant 112, 114,116. The sealant encapsulations 112, 114, 116 are contemplated toelectrically isolate the ends of the threaded members 96, 100 from theadjacent structures, particularly the metal brackets 66, 68.

As discussed above, FIG. 5 graphically illustrates a chamfered bracketcomponent 118. While the bracket 68, the first layer 74, the secondlayer 76, and the third layer 78 are shown as being separated from oneanother, elements 68, 74, 76, 78 are contemplated to be adhered to oneanother in a pre-cured state. As may be apparent, during curing, thesealant from the layers 74, 78 and the sealant beads 84, 86, 88 willmigrate to fill any voids adjacent thereto, thereby assuring, amongother things, a uniform, bubble-free connection.

As noted above, the embodiment(s) described herein are intended to beexemplary of the wide breadth of the present invention. Variations andequivalents of the described embodiment(s) are intended to beencompassed by the present invention, as if described herein.

What is claimed is:
 1. A chamfered bracket suitable for being connectedto a structural element made from a composite material, comprising: afirst surface and a second surface, the first surface being adapted forfacing the structural element; and a chamfer located on a first end ofthe bracket, wherein an angle is defined between a plane of the chamferand a plane of the first surface, the first surface of the bracket beingadapted to be disposed adjacent to a side of the structural element,wherein the chamfer defines a chamfer thickness as a distance measuredfrom a first position where the chamfer intersects the first surface toa second position where the chamfer intersects an end surface along aline normal to the plane defined by the first surface, wherein a bracketthickness is defined as a distance measured from the first surface tothe second surface along the line normal to the plane defined by thefirst surface, and wherein the chamfer thickness is less than thebracket thickness.
 2. The chamfered bracket of claim 1, wherein thechamfer is a first chamfer, the bracket comprising a second chamferlocated on a second end of the bracket.
 3. The chamfered bracket ofclaim 1, comprising at least one layer of sealant material applied tothe first surface, such that the sealant material occupies a spaceestablished between the chamfer and the structural element wheninstalled.
 4. The chamfered bracket of claim 3, further comprising apolyimide film positioned between two layers of the sealant material. 5.The chamfered bracket of claim 3, wherein the at least one layer ofsealant material comprises an interfay sealant.
 6. The chamfered bracketof claim 1, comprising at least one of titanium, alloys of titanium,aluminum, alloys of aluminum, iron, alloys of iron, steel, plastics,composite materials, and ceramics.
 7. The chamfered bracket of claim 1,wherein the angle is between about 20°-70°.
 8. The chamfered bracket ofclaim 1, wherein the chamfer thickness is at least one of greater thanabout 0.020 inches (0.51 mm), greater than about 0.025 inches (0.64 mm),greater than about 0.030 inches (0.76 mm), greater than about 0.035inches (0.89 mm), and greater than about 0.04 inches (1.02 mm).
 9. Thechamfered bracket of claim 1, wherein the ratio of the chamfer thicknessto the bracket thickness is at least one of about 0.50, about 0.45-0.55,about 0.40-0.60, or about 0.35-0.65.
 10. A method for repairing adamaged structural element made from a composite material, comprising:providing a bracket defining a first surface and a second surface, thefirst surface being adapted for facing the structural element, and achamfer located at a first end of the bracket, wherein an angle isdefined between a plane of the chamfer and a plane of the first surface;applying a sealant material to one of the first surface of the bracketand a side surface of the structural element; placing the bracketadjacent the side surface of the structural element such that thesealant material occupies a space established between the chamfer andthe structural element; and connecting the bracket to the structuralelement via a mechanical fastener.
 11. The method of claim 10, furthercomprising: applying a film to the sealant material.